Micro LED Unit Pixel Module With Stepped Layer for Stable Mounting
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Solution Overview
Problem
The challenge lies in mounting and handling micro LEDs, which are extremely small, making it difficult to directly mount light emitting diodes on a display panel effectively, leading to issues with reliability and failed installations in micro LED displays.
Innovation Solution
A unit pixel design featuring a transparent substrate with light emitting devices bonded by an adhesive layer, a step adjusting layer with a concave-convex pattern, and connection layers, allowing for stable mounting on a circuit board and preventing failed installations, along with a pixel module structure that includes these units for efficient display assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro LEDs are made extremely small to achieve high-resolution display, then display resolution is improved, but handling and mounting difficulty increases
Solution Approach 1:
The patent divides the micro LED array into modular unit pixels, each containing multiple sub-pixels (red, green, blue LEDs) arranged in a specific pattern. This segmentation allows the extremely small micro LEDs to be manufactured with high precision on a substrate first, then the entire unit pixel module can be handled and mounted as a larger, more manageable component, resolving the contradiction between achieving high display resolution through small LED size and the difficulty of handling individual micro LEDs during mounting
Solution Approach 2:
The patent implements a nested structure where multiple levels of organization are combined: individual micro LEDs are nested within unit pixels, which are then nested within pixel modules that can be mounted on the display panel. This nested approach allows the extremely small micro LEDs to maintain their high-resolution function while being contained within progressively larger structures that facilitate handling and mounting, effectively resolving the size-related handling difficulty
2Manufacturing precision
If a large number of micro LEDs are arranged on a single substrate to achieve high resolution, then display quality is improved, but reliability decreases due to increased failure risk
Solution Approach 1:
The patent segments the large array of micro LEDs into multiple independent unit pixels, where each unit pixel contains a complete set of sub-pixels (red, green, blue LEDs) that can function independently. This segmentation means that if one micro LED or even one unit pixel fails, the rest of the display continues to operate, thereby maintaining high display quality through dense arrangement while improving reliability through redundancy and modular independence
Solution Approach 2:
The patent changes the organizational parameter from individual micro LED mounting to unit pixel module mounting. By defining a unit pixel as a functional module containing multiple sub-pixels with specific electrical connections, the system transforms the failure mode from individual LED failure affecting the entire display to localized unit pixel failure that can be isolated and replaced without affecting other areas, thus improving installation reliability while maintaining high display quality
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
A unit pixel according to an embodiment of the present disclosure comprises: a transparent substrate; a plurality of light emitting diodes arranged on the transparent substrate; an adhesive layer for bonding the light emitting diodes to the transparent substrate; a step adjustment layer which covers the light emitting diodes and is bonded to the adhesive layer; and connection layers which are disposed on the step adjustment layer and are electrically connected to the light emitting diodes, wherein the step adjustment layer has an uneven pattern formed along the edge thereof.